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The worldwide automotive business is within the midst of main adjustments and challenges towards the pattern of electrification and intelligence. In keeping with the current statistics launched by a neighborhood auto business affiliation, the gross sales of China’s gasoline car market have declined for 3 consecutive years. With the intensification of the value struggle, some automobile firms have even withdrawn from the market. The auto components producers caught in it are dealing with the issue of learn how to survive and develop towards the more and more fierce competitors.
Yanfeng Auto Worldwide Automotive Expertise Co., Ltd. (hereinafter known as “Yanfeng Auto”) is a number one Chinese language automotive components provider specializing in automotive inside and exterior trim, automobile seats, cabin electronics and security techniques. Headquartered in Shanghai, Yanfeng Auto has 9 R&D facilities, greater than 240 factories and technical facilities in 20 international locations world wide, with over 55,000 workers. Dealing with challenges, Yanfeng Auto’s method is to work with firms like IBM with superior know-how, business expertise and technical experience to speed up its personal data-driven digital transformation to cut back price, enhance effectivity and scale for company-wide innovation.
State of affairs 1: Robotically convert large exterior basic orders to inner orders with the pure language studying functionality of IBM Watson Discovery
Yanfeng Auto receives an enormous variety of orders from automakers and downstream producers on daily basis, and it beforehand needed to manually convert exterior basic orders to inner orders primarily based on expertise. In every manufacturing facility, it took a mean of 150 minutes a day for 2 employees members to kind the orders manually, accompanied by 15% classification errors. That presents huge challenges for the corporate when it comes to labor price and effectivity.
Leveraging the highly effective pure language studying functionality of IBM Watson Discovery and the hands-on assist of IBM Buyer Success Supervisor (CSM) staff, Yanfeng Auto efficiently constructed up an AI mannequin that was skilled with its combined information of structured information and unstructured textual content, masking 180 million historic information, with over 200 permutations and mixtures. The mannequin has discovered the principles behind the inner orders similar to basic orders. The AI mannequin helps the corporate notice a completely computerized execution course of with out handbook operation, rising the order classification accuracy price from 85% to 97%.
State of affairs 2: Notice high-speed transmission of large information between department manufacturing workshops and headquarters with Aspera Module of IBM Cloud Pak for Integration, establishing information basis for clever stock platform with predictability.
The Clever Manufacturing Division of Yanfeng Auto hopes to work with IBM CSM staff to discover the best way of increase its clever stock platform with predictive capabilities. To drive predictive choice making and computerized recognition, they want a considerable amount of information throughout the corporate for AI mannequin coaching. Nonetheless, the primary roadblock is its outdated manner of information transmission.
To take care of real-time situational consciousness of the components stock in varied manufacturing workshops in additional than 240 factories world wide, Yanfeng Auto must rapidly transmit again to headquarters the 1000’s of real-time photographs taken at every plant. Beforehand, the Clever Manufacturing Division used the standard copy and paste technique to switch the photograph recordsdata by batches. As a consequence of gradual transmission pace, huge community delays, and critical packet loss, they needed to manually choose and replica the photograph recordsdata by batches and repeat the method a number of instances. This was not solely time-consuming but in addition made it simple to make errors. On the identical time, if the transmission was interrupted, it couldn’t be reconnected and resume transmission robotically, nor might they customise the transmission pace, or totally make the most of the transmission bandwidth of the spine community.
With assist of IBM CSM staff, Yanfeng Auto efficiently deployed Aspera Module of IBM Cloud Pak for Integration inside solely someday to construct up a light-weight enterprise-level file switch resolution for Yanfeng Auto, which elevated its file switch pace by 10 instances, saved handbook ready time, averted human errors, realized computerized transmission resumption and computerized community reconnection. With this resolution, Yanfeng Auto now can dynamically configure transmission bandwidth and pace restrict with out affecting the efficiency of its ERP core system and maximize the transmission effectivity of its real-time monitoring recordsdata, laying the information basis for realizing the division’s imaginative and prescient of increase an clever stock platform with predictive capabilities.
State of affairs 3: Break the operational bottleneck attributable to Kafka, an open-source information extraction instrument. With Occasion Streams Module of IBM Cloud Pak for Integration, you possibly can simplify the method of extremely out there information extraction.
Yanfeng Auto has beforehand deployed an open-source Kafka cluster in every department manufacturing facility to extract information from a number of real-time manufacturing information in its MES system and supply them to the MI Kanban (Dashboard) System of every manufacturing facility for question and show. Nonetheless, this open-source system poses a number of operational complexities.
For instance, for every handbook set up, deployment, configuration, improve, and upkeep, it might take days or even weeks and incur an enormous labor price. Furthermore, it was not in a position to make sure enterprise-level safety and excessive availability, and it didn’t assist pure integration with the core enterprise techniques and the frequent manufacturing techniques. Lastly, there was no Kafka technical assist or after-sales assure, ensuing within the want for ongoing funding in employees coaching and professional consulting providers.
With the assist of IBM CSM staff, Yanfeng Auto has efficiently adopted Occasion Streams Module of IBM Cloud Pak for Integration in one among its factories as a prototype for real-time information extraction. The info-generating utility extracts information—similar to components manufacturing shifts, manufacturing portions, demand portions, rework portions, sequencing and different related manufacturing information—from the MES system and sends them to the corresponding information matter channel. Purposes that extract information can use the information straight by subscribing to the corresponding matter channel of Occasion Streams. The MI Skynet Kanban (Dashboard) system can choose specified desk fields for subsequent dashboard show and early warning evaluation.
By deploying Occasion Streams, the enterprise-level information extraction resolution, Yan Feng can obtain “one-click” deployment, out-of-the-box use, zero downtime rolling upgrades, and all the time have the most recent secure model of Kafka. Occasion Streams comes with a graphical operation interface, which requires little extra expertise coaching. It additionally takes benefit of high-security, geo-replication, and enterprise-grade catastrophe restoration capabilities of the product. Furthermore, different functionalities like superior schema registries and wealthy Kafka connectors and extensible REST APIs make it simple to scale. As well as, IBM gives enterprise-level after-sales service, professional session, and well timed troubleshooting, serving to the shopper to acquire the technical experience they want.
State of affairs 4: Notice clever manufacturing capability estimation and planning for core manufacturing tools with Determination Optimization Module of IBM Cloud Pak for Information to cut back prices and improve effectivity.
In auto components manufacturing, injection molding is without doubt one of the essential processes. Yanfeng Auto gives varied automakers with inside components similar to instrument panels, which require a core tools of injection molding machine to supply. Because of the completely different specs of the instrument panels of assorted car fashions, the manufacturing course of requires tools changeovers. For instance, when the fabric is switched from black to white, the tools must be cleaned; when switching from white to black, it doesn’t have to be cleaned. Switching from gold to pink requires different extra actions.
Tools switching won’t solely contain price, however have an effect on manufacturing scheduling and stock administration. For instance, how do they decide the optimum financial batch dimension of various merchandise whereas lowering stock prices? How do they stability the capability of a number of machines for a complete yr whereas assembly buyer wants? How can they estimate the capability of the machine to higher modify the plan, maximize the effectivity of the machine, improve productiveness, and scale back additional time? How will they be sure that the plan will be carried out in manufacturing and that adjustments will be responded to in a well timed method after they come？
Within the context of the continual growth and alter of demand for varied auto components, and the truth that productiveness and manufacturing sources are very restricted, the standard manufacturing planning technique is predicated on expertise and handbook calculation, which simply causes issues similar to low manufacturing effectivity, excessive stock price, heavy labor burden and extra. All of this might significantly have an effect on the manufacturing effectivity of the corporate, so it’s essential to seek out new methods to develop affordable manufacturing planning and scheduling schemes.
After rounds of discussions with consultants from IBM CSM staff, IBM Specialists Lab and IBM China Improvement Lab, IBM consultants developed a complete and agile resolution for Yanfeng Auto with Determination Optimization Module of IBM Cloud Pak for Information. The answer has two complementary components—the general multi-machine, multi-month planning scheme and the single-month tremendous scheduling scheme.
The answer helps practically 100 employees in additional than 20 factories to plan the capability of tons of of injection molding machines with extremely detailed and particular plans. Every define plan is accompanied by an correct scheduling plan, which is very sensible for follow-up steering for manufacturing. It’s also an agile resolution: planning a set of schemes solely takes just a few or dozens of minutes, significantly bettering the responsiveness to future adjustments. If the client wants or manufacturing sources change, Yanfeng Auto can modify the plan at any time. Based mostly on an agile and customary platform, this business-friendly resolution will be simply tailored and scaled to different manufacturing amenities and different related areas.
The IBM CSM staff has accompanied Yanfeng Auto on its journey of digital and clever transformation for 2 years: from the preliminary realization of computerized conversion of exterior orders to inner orders; from fixing the issue of high-speed information transmission in department factories world wide to the headquarters; from changing its open-source instrument with an IBM enterprise instrument constructed on open supply to simplify its IT operational complexity for high-availability information extraction, to the most recent AI-powered options to understand manufacturing capability estimation and planning for its core manufacturing tools. From information integration and administration to making use of AI to its enterprise course of and planning, Yanfeng Auto has been actively co-creating with IBM technical and enterprise consultants to show applied sciences to tangible enterprise values.
Yanfeng Auto is without doubt one of the business pioneers in China to handle enterprise challenges with a “data-first” technique. Yanfeng Auto can also be the pioneer shopper of IBM in China that has been working carefully with IBM to co-create first-of-a-kind scenario-based options with IBM Cloud and AI applied sciences.
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About Yanfeng Auto
Yanfeng Auto Worldwide Automotive Expertise Co., Ltd. (known as “Yanfeng Auto”) is a world automotive components provider, dedicated to offering carmakers and different customers with inside and seating options that meet the wants of immediately’s and tomorrow’s driving, redefining the best way you calm down, work and play within the automobile. Headquartered in Shanghai, the corporate has 9 R&D bases, greater than 4,200 R&D groups, greater than 240 factories and technical facilities in 20 international locations world wide, and greater than 55,000 workers worldwide, offering international car producers with the design, growth and manufacture of auto components merchandise. With product innovation and forward-looking analysis, Yanfeng Auto will assist automakers discover the longer term, convey higher human-car interplay expertise to international auto customers, and actively promote the evolution of automobile driving expertise.
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